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Selection and Optimization of Pure and Mixed Working Fluids for Low Grade Heat Utilization Using Organic Rankine Cycles

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Selection and Optimization of Pure and Mixed Working Fluids for Low Grade Heat Utilization Using Organic Rankine Cycles Downloaded from orbit.dtu.dk on: Oct 06, 2021 Selection and optimization of pure and mixed working fluids for low grade heat utilization using organic Rankine cycles Andreasen, Jesper Graa; Larsen, Ulrik; Knudsen, Thomas; Pierobon, Leonardo; Haglind, Fredrik Published in: Energy Link to article, DOI: 10.1016/j.energy.2014.06.012 Publication date: 2014 Document Version Early version, also known as pre-print Link back to DTU Orbit Citation (APA): Andreasen, J. G., Larsen, U., Knudsen, T., Pierobon, L., & Haglind, F. (2014). Selection and optimization of pure and mixed working fluids for low grade heat utilization using organic Rankine cycles. Energy, 73, 204–213. https://doi.org/10.1016/j.energy.2014.06.012 General rights Copyright and moral rights for the publications made accessible in the public portal are retained by the authors and/or other copyright owners and it is a condition of accessing publications that users recognise and abide by the legal requirements associated with these rights. Users may download and print one copy of any publication from the public portal for the purpose of private study or research. You may not further distribute the material or use it for any profit-making activity or commercial gain You may freely distribute the URL identifying the publication in the public portal If you believe that this document breaches copyright please contact us providing details, and we will remove access to the work immediately and investigate your claim. Selection and optimization of pure and mixed working fluids for low grade heat utilization using organic Rankine cycles J.G. Andreasen∗, U. Larsen, T. Knudsen, L. Pierobon, F. Haglind Technical University of Denmark, Department of Mechanical Engineering Building 403, Nils Koppels All´e, DK-2800 Kgs. Lyngby, Denmark Abstract We present a generic methodology for organic Rankine cycle optimization, where the working fluid is included as an optimization parameter, in order to maximize the net power output of the cycle. The method is applied on two optimization cases with hot fluid inlet temperatures at 120◦C and 90◦C. Pure fluids and mixtures are compared to see how mixed working fluids affect performance and important design parameters. The results indicate that mixed working fluids can increase the net power output of the cycle, while reducing the pressure levels. The maximum net power output is obtained by fluids with a critical temperature close to half of the hot fluid inlet temperature. For some mixtures we find the maximum net power when the temperature glide of condensation matches the temperature increase of the cooling water, while for other mixtures there are large differences between these two parameters. Ethane is a fluid that obtains a large net power increase when used in mixtures. Compared to pure ethane, an optimized ethane/propane mixture attains a 12.9% net power increase when the hot fluid inlet temperature is 120◦C and a 11.1% net power increase when the hot fluid inlet temperature is 90◦C. Keywords: organic Rankine cycle, genetic algorithm, fluid selection, zeotropic mixtures, low grade heat, geothermal 1. Introduction The organic Rankine cycle (ORC) is a technology, that can produce mechanical power from various heat sources. Compared to the traditional steam Rankine cycle the ORC has ∗Corresponding author. Tel.: +45 45 25 41 23 Email address: [email protected] (J.G. Andreasen) Nomenclature Acronyms Subscripts and superscripts GWP Global warming potential boil Boiling HMIS Hazardous Materials Identification System cond Condenser ODP Ozone depletion potential cool Cooling water ORC Organic Rankine cycle exp Expander g Glide of condensation Greek symbols hf Hot fluid ∆ Difference I First law/thermal Effectiveness, [%] i Input η Efficiency, [%] min Minimum NET Net Symbols n Normalized A Area, [m2] o Out cp Specific heat capacity, [kJ/kgK] p Polytropic h Specific enthalpy, [kJ/kg] pp Pinch point m_ Mass flow rate, [kg/s] pump Pump n Number of discretization points, [-] ref Reference P Pressure, [bar] s Isentropic Q_ Heat transfer rate, [kW] sat Saturated s Entropy, [kJ/kgK] sc Subcritical T Temperature, [◦C] sh Superheated U¯ Average overall heat transfer coefficient, [kW/m2K] tc Transcritical V_ Volume flow rate, [m3/s] wf Working fluid W_ Mechanical power, [kW] X Mole fraction, [-] x Vapour quality, [-] several advantages when considering utilization of low temperature heat [1]. This makes the ORC suited for environmentally-friendly power conversion from geothermal heat sources, concentrated solar energy, waste heat streams and as bottoming cycles for power plants. An important part of the optimization and design of an ORC is the working fluid selec- tion, since the properties of the working fluid affect both cycle performance and component design. The volume flow ratio, enthalpy drop and Mach number are some important param- eters when considering expander design, while thermal conductivity and viscosity are key variables in heat exchanger design. Hazard levels, ozone depletion potential (ODP), global warming potential (GWP) and thermal stability must also be considered. When choosing a working fluid for an ORC, it is therefore necessary to consider many different parameters, in order to reach a feasible design. For example, it is possible that a thermodynamically beneficial working fluid requires infeasibly large heat exchanger areas or an overly expensive expander (e.g. a multi-stage axial turbine). The review on fluid selection studies recently provided by Bao and Zhao [2], gives an overview of the abundant literature which is available on fluid selection for pure fluids. Binary working fluids have been studied far less, despite the available literature suggesting possible performance benefits when zeotropic mixtures 2 are used in ORCs. The non-isothermal phase change of zeotropic mixtures, can be utilized to optimize the heat transfer processes in the evaporator and the condenser thus increasing the effi- ciency of the ORC [3]. Heberle et al. [4] optimized subcritical ORCs using the mixtures: isobutane/isopentane and R227ea/R245fa, as working fluids. The analysis showed that the second law efficiency of the best isobutane/isopentane mixture was 8% higher than that of pure isobutane. The best R227ea/R245fa mixture showed 0.8% higher second law efficiency than pure R227ea. For the isobutane/isopentane mixture, Heberle et al. [4] also showed that the condenser UA-value peaked with the second law efficiency, while the UA-values for the preheater and the evaporator remained close to constant over a range of mixture compositions. Trapp and Colonna [5] maximized the net power output of an ORC for low grade waste heat recovery from a pre-combustion CO2 capture process as part of an integrated gasifica- tion combined cycle power plant. The waste heat stream was a 140◦C syngas/water mixture which partly condensed as heat was transferred from the waste heat stream to the ORC. For this unconventional heat source they showed that it was thermodynamically beneficial to have a supercritical boiler pressure and/or a binary zeotropic working fluid in the ORC. The results of an exergy analysis indicated that the exergetic efficiency of the condenser increased by 31% when a binary mixture was used instead of a pure fluid, and that the exer- getic efficiency of the primary heat exchanger (boiler) was increased by 4-6% when an ORC with a supercritical boiler pressure was used instead of a subcritical ORC. An estimation of the required condenser heat transfer area indicated that a larger condenser is needed for mixtures than for pure working fluids. Chys et al. [6] optimized a large number of working fluids (pure fluids, binary mix- tures and three-component mixtures) in ORCs. For their low temperature heat source they optimized eight different binary mixtures of hydrocarbons and refrigerants to reach maxi- mum thermal efficiency. For cyclohexane the thermal efficiency increased from 10.85% to 11.57% when isopentane was combined with cyclohexane to form a binary zeotropic working fluid, and a further increase to 11.74% was obtained when isohexane was added to form a three-component working fluid mixture. Papadopoulos et al. [7] recently presented a fluid selection method where the Computer Aided Molecular Design approach was used to find optimal molecular structures for fluids used in binary working fluid mixtures. The method was applied to maximize the exergetic efficiency of an ORC utilizing a heat stream with an inlet temperature at 95◦C and yielded 10 3 potentially optimal fluid mixtures containing neopentane and/or fluorinated hydrocarbons. A fluid selection and optimization study of ORCs, considering a large group of binary mixtures as possible working fluids, combined with an evaluation of parameters which affect the design of components, for a non-condensing (temperature independent cp) heat source, has not yet been published in the scientific literature. Previous studies on binary mixtures in ORCs concerned optimization and preliminary component design for specific fluid mixtures, while other studies have considered many different binary mixtures with a primary focus on efficiency maximization. This paper provides an ORC optimization analysis where both pure fluids and mixtures are considered as possible working fluids. Two liquid water streams with inlet temperatures at 120◦C and 90◦C representing geothermal heat sources or industrial waste heat streams are chosen as the basis of the analysis. These low temperatures are chosen, since mixtures have shown beneficial performance compared to pure fluids when the hot fluid inlet temperature is low [3{7]. A systematic methodology using a genetic algorithm optimizer is developed to find promising pure fluids and mixtures for the maximization of the net ORC power output. Both subcritical-saturated, subcritical-superheated and transcritical ORCs are considered as possible solutions. The best candidates are evaluated based on: thermodynamic per- formance, pressure levels, volume flow ratio over the expander, a turbine size parameter, UA¯ -values, fluid hazard levels and GWP, which are the critical parameters for the expander design, heat exchanger design, safety and the environment.
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